Method for manufacturing punch capable of punching and embossing simultaneously

ABSTRACT

Disclosed is a method for manufacturing a punch, which includes the steps of injection-molding a jig with melted materials so that a lower plate and an upper plate are integrally formed at least partially to connect cutting holes to be formed in the lower and upper plates and also so that a convex embossment is formed on the lower plate; cutting a connection portion of the lower and upper plates to form a gap in which a sheet member is to be supplied so that the cutting holes are separated between the lower and upper plates, the cutting work being conducted so that an upper surface of the lower plate is formed to have a height greater than an upper surface of the formed convex embossment; and assembling a punching member, which includes at least one first punch pin passing through the cutting holes to punch the sheet member and form a predetermined pattern therein and a second punch pin having a concave embossment at a front end thereof in correspondence to the convex embossment, to the jig.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of co-pending U.S. patentapplication Ser. No. 10/886,391, filed Jul. 6, 2004, which isincorporated by reference herein in its entirety.

FIELD OF THE INVENTION

The present invention relates to a punch, and more particularly to amethod for manufacturing a punch capable of simultaneously punching andembossing a sheet member such as a card, a letter paper, a picture, aboard, or a paper in a predetermined pattern.

BACKGROUND OF THE INVENTION

A punch generally includes a jig having a cutting hole of apredetermined pattern, a base for supporting the jig below it, and apunching member having a sharp cutting blade which slides through thecutting hole of the jig. This punch punches a sheet member according tothe pattern of the cutting hole when the punching member passes throughthe jig by means of the stroke operation for descending the punchingmember toward the jig while the predetermined sheet member is put into acorresponding punching area of the jig.

In the punch configured as mentioned above, it is also possible to forman embossing design of a predetermined pattern in the sheet member if aconvex embossment (or, a concave embossment) of a predetermined patternis formed on the surface of the jig and a concave embossment (or, aconvex embossment) in correspondence with the convex embossment (or, theconcave embossment) is formed at the front end of the punching member.

However, since the conventional punch is configured just to performeither a punching function or an embossing function, a user shouldhandle two kinds of punches to decorate a sheet member with a punchingdesign and an embossing design together. In addition, when using eachpunch, the user may measure a punching point and an embossing point justwith the eye whenever conducting the punching or embossing work, so theobtained punching and embossing patterns are irregular, and even acomplex design is impossible to work.

SUMMARY OF THE INVENTION

The present invention is designed to solve the problems of the priorart, and therefore it is an object of the present invention to provide amethod for manufacturing a punch capable of simultaneously punching andembossing a sheet member in a predetermined pattern by just one stroke.

Another object of the invention is to provide a method for manufacturinga punch capable of forming various punching and embossing designs, whichis impossible in the prior art, by mixing a punching member with pinsfor embossing in various ways.

In order to accomplish the above object, the present invention providesa method for manufacturing a punch, comprising the following steps of:(a) injection-molding a jig with melted materials so that a lower plateand an upper plate are integrally formed at least partially to connectlower and upper cutting holes to be formed on the lower and upper platesrespectively and also so that a convex embossment is formed on the lowerplate; (b) cutting a connection portion of the lower and upper plates toform a gap through which a sheet member is to be supplied so that thelower and upper cutting holes are separated on the lower and upperplates respectively, and so that an upper surface of the lower plate isformed at the position higher than an upper surface of the convexembossment; and (c) assembling a punching member, which includes a firstpunch pin passing through the cutting holes to punch the sheet memberand form a predetermined pattern therein and a second punch pin having aconcave embossment at a front end thereof in correspondence to theconvex embossment, to the jig.

Preferably, a trimming hole on the lower plate for cutting a marginaledge of the sheet member are integrally formed with a guide opening onthe upper plate for guiding vertical movement of a punch pincorresponding to the trimming hole in the step (a), and the trimminghole and the guide opening are separated by cutting in the step (b).

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects and aspects of the present invention will become apparentfrom the following description of embodiments with reference to theaccompanying drawing in which:

FIG. 1 is an exploded perspective view showing a punch according to apreferred embodiment of the present invention;

FIG. 2 is a perspective view showing the punch of FIG. 1, which isassembled;

FIG. 3 is a partially sectioned perspective view showing an innerconfiguration of a jig of FIG. 1 in detail;

FIG. 4 is a side view schematically showing a type of punching memberprovided to the punch of the present invention;

FIG. 5 is a partially exploded perspective view showing a punchingmember in correspondence with FIG. 3;

FIG. 6 is a plane view showing an example of a punching and embossingpattern formed in a sheet member according to the present invention;

FIG. 7 is a side view schematically showing another type of punchingmember provided to the punch of the present invention;

FIG. 8 is a partially exploded perspective view showing a punchingmember according to the type of FIG. 7;

FIG. 9 is a plane view showing a front end surface of an integratedpunch pin of FIG. 8;

FIG. 10 is a partially sectioned perspective view showing an example ofthe jig in correspondence with FIG. 8;

FIG. 11 is a plane view showing another example of a punching andembossing pattern formed in the sheet member according to the presentinvention;

FIG. 12 is a plane view showing that a sheet member is supplied to apunching area for usage of the punch according to the present invention;

FIG. 13 is a perspective view showing a jig of a punch according toanother embodiment of the present invention;

FIG. 14 is a sectioned perspective view showing the jig incorrespondence with FIG. 13;

FIG. 15 is a plan view showing the jig in correspondence with FIG. 13;

FIG. 16 is a sectional view showing the jig in correspondence with FIG.14;

FIG. 17 is a perspective view showing a punching member incorrespondence with the jig of FIG. 13;

FIG. 18 is a plane view showing an example of a punching and embossingpattern formed in the sheet member according to another embodiment ofthe present invention;

FIG. 19 is a flow chart showing a method for manufacturing a punchaccording to the present invention;

FIG. 20 is a sectional view showing a mold corresponding to the jig ofFIG. 16 according to the method of the present invention; and

FIG. 21 is a sectional view showing a preform of the jig taken from themold of FIG. 20 according to the method of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Hereinafter, the present invention will be described in more detailreferring to the drawings.

FIG. 1 is an exploded perspective view showing a punch according to apreferred embodiment of the present invention, and FIG. 2 is aperspective view showing the punch of FIG. 1 in an assembled state.

Referring to FIGS. 1 and 2, the punch of the present invention includesa jig 100 having a punching area 101, a base 105 for supporting the jig100, a punching member 115 for punching and embossing a sheet membersupplied to the jig 100 with selectively descending against the jig 100,and a handle 130 used for pressing the punching member 115.

The jig 100 supports the supplied sheet member and gives the punchingarea 101 for punching and embossing the sheet member in a predeterminedpattern. As exemplary shown in FIG. 3, the punching area 101 of the jig100 has at least one cutting hole 101 a of a predetermined pattern andat least one convex embossment 102 of a predetermined pattern at aposition spaced apart from the cutting hole 101 a. Here, the punch ofthe present invention is not limited to the above example, but may bemodified so that a concave embossment of a predetermined pattern isformed in the jig 100, of course.

Preferably, the jig 100 may have an upper plate 100 a and a lower plate100 b, which are faced in parallel with each other so that a gap G isinterposed between them for insertion of a sheet member to be punched.In this case, the cutting hole 101 a is formed in the upper plate 100 aand the lower plate 100 b respectively, and the convex embossment 102 isformed only in the lower plate 100 b. Additionally, a guide hole 101 bfor guiding movement of a corresponding punch pin may be formed in theupper plate 100 a in correspondence to the convex embossment 102.

The base 105 supports the jig 100 below it and gives a support surfacefor supplying a sheet member to the punching area 101.

The punching member 115 is installed to be vertically movable againstthe jig 100, and acts for punching and embossing a sheet member suppliedto the jig 100 when it descends. For convenient handling of the punchingmember 115, an elastic body 110 for elastically biasing the punchingmember 115 upward is interposed between the punching member 115 and thejig 100. Preferably, the elastic body 110 is a spring, which issymmetrical to the punching area 101 and biases the punching member 115upward with being held by a plurality of protrusions 103 formed on theupper plate 100 a of the jig 100.

The punching member 115 has an assembly of punch pins, which arerespectively corresponding to the cutting hole 101 a and the convexembossment 102 of the jig 100 and protruded downward. The punchingmember 115 may be classified into two types respectively shown in FIGS.4 and 7 according to the structure of the punch pin assembly.

The punching member 115 schematically shown in FIG. 4 has a punch pinassembly, composed of at least one punch pin 116 having a cutting bladeat its front end, and at least one second punch pin 117 having a concaveembossment (or, a convex embossment) at its front end and having a bodyseparated from the first punch pin 116. The punching member 115 conductspunching and embossing to a sheet member at the same time when itdescends against the jig 100. Here, the first punch pin 116 ispreferably longer than the second punch pin 117 for easier punching.More specifically, a length difference d between the first punch pin 116and the second punch pin 117 is preferably larger than the gap G of thejig 100.

FIG. 5 shows an example of the punching member 115 corresponding to thejig 100 of FIG. 3. The punching member 115 of FIG. 5 is alsosubstantially corresponding to the type of FIG. 4. Referring to FIG. 5,in the punching member 115, a first punch pin 116 corresponding to thecutting hole 101 a of the jig 100 and having a cutting blade 116 a atits front end and a second punch pin 117 having a concave embossmentcorresponding to the convex embossment 102 of the jig 100 at its frontend 117 a are arranged in a predetermined pattern. The first punch pin116 is longer than the second punch pin 117 as much as at least the gapG of the jig 100. Additionally, the punching member 115 may be furtherprovided with a rim cutting pin 118 for cutting a rim portion of thesheet member in a predetermined pattern.

When using the punching member 115 and the jig 100 configured asmentioned above, at a stroke of the punching member 115, the first punchpin 116 passes through the cutting hole 101 a of the jig 100 to punchthe sheet member, and then the second punch pin 117 is compressed withthe convex embossment 102 of the jig 100 with the sheet memberpositioned between them to emboss the sheet member. Thus, as shown inFIG. 6, a punching pattern 2 and an embossing pattern 3 are formed inthe sheet member 1 at the same time. In addition, the rim portion isalso cut away in a predetermined pattern.

Meanwhile, FIG. 7 shows a punching member 215 having an integrated punchpin 216, in which an embossing unit and a punching unit are providedintegrally. Referring to FIG. 7, at least one integrated punch pin 216is arranged to the punching member 215 in a predetermined pattern, andother punch pins for either punching or embossing may also be furtherprovided. The integrated punch pin 216 includes an embossing unit ofwhich a diameter is relatively large, and a punching unit protruded fromone side of the embossing unit and extended to a front end thereof witha diameter relatively smaller than the embossing unit. In addition, aconcave embossment (or, a convex embossment) of a predetermined patternis formed on the front end surface of the embossing unit of theintegrated punch pin 216, and a cutting blade is formed at the front endsurface of the punching unit, so the integrated punch pin 216 punchesand embosses the sheet member at the same time when it descends againstthe corresponding jig. In the integrated punch pin 216, the length Lfrom the front end surface of the embossing unit to the front endsurface of the punching unit is preferably greater than the gap G of thejig for better punching work.

FIG. 8 shows an example of a punching member 215 corresponding to thetype of FIG. 7 in detail, and FIG. 10 shows a jig 300 corresponding tothe punching member 215 as an example.

Referring to FIG. 8 first, the punching member 215 is provided with atleast one integrated punch pin 216 of a predetermined pattern, whichconducts punching and embossing at the same time. Additionally, thepunching member 215 may be further provided with other punch pins 217for punching only without embossing, and a rim cutting pin 118 forcutting away a rim of the sheet member.

The integrated punch pin 216 includes, as shown in FIG. 9, an embossingunit 219 having a first front end surface 219 a on which a concaveembossment corresponding to the convex embossment 302 (see FIG. 10) ofthe jig 300 is formed, and a punching unit 218 having a second front endsurface on which a cutting blade corresponding to the cutting hole 301 cof the jig 300 is formed.

The first front end surface 219 a of the embossing unit 219 is at leastcorresponding to a partial sectional area of the integrated punch pin216, and the concave embossment corresponding to the convex embossment302 of the jig 300 is formed thereon. In addition, the second front endsurface 218 a of the punching unit 218 is corresponding to a remainedsectional area of the integrated punch pin 216, and the cutting bladecorresponding to the cutting hole 301 c of the jig 300 is formedthereon. The second front end surface 218 a is further protruded ratherthan the first front end 219 a. Preferably, the second front end surface218 a of the punching unit 218 may be perpendicularly protruded from thecenter portion of the first front end surface 219 a of the embossingunit 219 so that a punching pattern is formed at the center of anembossing pattern.

The jig 300 of FIG. 10, which corresponds to the punching unit 215,includes a convex embossment 302 of a predetermined pattern formed onthe lower plate 300 b of the jig 300, and a cutting hole 301 c of apredetermined pattern formed in the lower plate 300 b at a positionadjacent to the convex embossment 302. Preferably, a guide hole 301 bfor guiding movement of the punch pin corresponding to the convexembossment 302 is formed in the upper plate 300 a.

A position of the convex embossment 302 adjacent to the cutting hole 301c may be located out of the convex embossment 302, or at the center ofthe convex embossment 302. Here, if the cutting hole 301 c is formed topass through the center of the convex embossment 302, it is possible toobtain a design in which a punching pattern is formed at the center ofan embossing pattern.

Additionally, it is also possible that cutting holes 301 a of apredetermined pattern corresponding to other punch pins 217 of thepunching member 215, not adjacent to the convex embossment 302, areformed in the upper and lower plates 300 a and 300 b.

When using the punching member 215 and the jig 300 configured as above,at the stroke of the punching member 215, the punching unit 218 of theintegrated punch pin 216 passes through the cutting hole 301 c of thejig 300 to punch the sheet member, and then the concave embossment ofthe embossing unit 219 of the integrated punch pin 216 is compressedwith the convex embossment 302 of the jig 300 with the sheet memberinterposed therebetween to emboss the sheet member. Thus, as shown inFIG. 11, it is possible to obtain a design in which a punching pattern 2passing through an embossing pattern 3 is formed together with otherpunching patterns 2, and a rim portion is additionally cut away in apredetermined pattern.

In addition to that, a button member 120 may be combined upon thepunching member 115 or 215. The button member 120 is covered by a cap125, which is combined with the base 105 with an open top, so an upperportion of the button member 120 is partially exposed. A rim portion ofthe button member 120 around the exposed upper portion is supported bythe cap 125 so as to prevent the button member 120 from being deviatedout due to an elastic force applied to the punching member 115 or 215.The cap 125 is combined to the lower base 105 with covering not only thebutton member 120 but also the punching member 115 or 215 and theelastic body 110 in a bundle. According to this configuration, a usermay conveniently move the punching member 115 or 215 downward toward thepunching area 101 of the jig 100 or 300 by downwardly pressing thebutton member 120 exposed outward.

Preferably, the button member 120 is pressed by using the handle 130pivotably connected to one side of the base 105 by means of a hinge 106,which ensures the user to descending the button member 120 more easily.

Now, operation of the punch configured as mentioned above according to apreferred embodiment of the present invention will be described.

First, as shown in FIG. 12, a sheet member is put in the punching area101 of the jig 100 or 300. Then, a user pushes the handle 130 downwardby hand, so the handle 130 is pivoted against the base 105 to press thebutton member 120 downward. Then, the punching member 115 or 215 alsodescends toward the punching area 101 of the jig 100 or 300 togetherwith the button member 120, thereby punching and embossing the sheetmember in a predetermined pattern.

More specifically, in case the punching member 115 is provided with thefirst punch pin 116 having the cutting blade 116 a and the second punchpin 117 having the concave embossment 117 a, and the cutting hole 110 acorresponding to the first punch pin 116 and the convex embossment 102corresponding to the concave embossment 117 a are formed in the upperand lower plates 100 a and 100 b of the jig 100, the first punch pin 116passes through the cutting hole 101 a of the upper plate 100 a of thejig 100, the sheet member 1, and the cutting hole 101 a of the lowerplate 100 b subsequently, thereby punching the sheet member, when thepunching member 115 descends. After that, the second punch pin 117descends through the guide hole 101 b of the upper plate 100 a so as tocompress the sheet member 1 between the second punch pin 117 and theconvex embossment 102, thereby embossing the sheet member 1.

In addition, in case the punching member 215 is provided with theintegrated punch pin 216, which includes the embossing unit 219 havingthe first front end surface 219 a on which the concave embossment isformed and the punching unit 218 having the second front end surface 218a on which the cutting blade is formed, and the convex embossment 302corresponding to the concave embossment is formed on the jig 300, thesecond front end surface 218 a of the punching unit 218 passes throughthe guide hole 301 b of the upper plate of the jig 300, the sheet member1 and the cutting hole 301 c of the lower plate subsequently, therebypunching the sheet member 1, while the punching member 215 descends.After that, the first front end surface 219 a of the embossing unit 219compresses the sheet member 1 between the first front end surface 219 aand the convex embossment 302 of the jig 300, thereby embossing thesheet member 1.

FIGS. 13 to 15 show a jig 400 of a punch according to another embodimentof the present invention. FIG. 17 shows a punching member 450corresponding to the jig 400.

The jig 400 includes a lower plate 410 on which lower cutting holes 411of a predetermined pattern, a convex embossment 412 and a trimming hole413 for cutting a marginal edge of a sheet member to be punched areformed.

In addition, the jig 400 includes an upper plate 420 facing the lowerplate 410 with a gap G between them, where upper cutting holes 421having the same pattern as the lower cutting holes 411 and a guideopening 422 for guiding vertical movement of punch pins corresponding tothe convex embossment 412 and the trimming hole 413 are formed.

The punching member 450 shown in FIG. 17 has a cutting blade formed atits front end, and the punching member 450 includes at least one firstpunch pin 451 passing through the upper and lower cutting holes 421 and411, a second punch pin 452 having a concave embossment 453corresponding to the convex embossment 412 at its front end and guidedby the guide opening 422, and a third punch pin 454 having a cuttingblade at its front end and passing through the trimming hole 413. Here,the first and third punch pins 451 and 454 are preferably formed to havea longer length than the second punch pin 452.

When a sheet member 1 is supplied between the lower plate 410 and theupper plate 420 and then the punch member 450 is pressed, the first andthird punch pins 451 and 454 pass through the upper and lower cuttingholes 421 and 411 and the trimming hole 413 to punch the sheet member,which may make a punching design in a predetermined pattern 12 as shownin FIG. 18. At the same time, as the second punch pin 452 descends andpresses the sheet member against the convex embossment 412, an embossingpattern 13 as shown in FIG. 18 may be obtained.

According to this embodiment, as well understood from FIG. 16, theconvex embossment 412 formed on the lower plate 410 has a height lowerthan an upper surface 410 a, that is a surface on which the sheet memberis placed, of the lower plate 410 by a predetermined distance D. Thisconfiguration may be realized by a specific punch manufacturing methodof the present invention.

A reference numeral 403 denotes protrusions, which are substantiallyidentical to the protrusions 103 of FIG. 3 and not described in detailhere.

In the method for manufacturing the punch according to this embodiment,a manufacture process of the jig 400 is shown in FIG. 19. Referring toFIG. 19, a mold corresponding to the shape of the jig 400 is prepared(S100). FIG. 20 is a sectional view showing a preferable example of themold 500 corresponding to a section of the jig of FIG. 16.

Inner spaces S1, S2 and S3 of the mold 500 are filled with materials,for example melted zinc that will be made into a jig. According to thepresent invention, the lower plate 410 and the upper plate 420 of thejig 400 are not individually molded in separate molds but integrallymolded in the spaces S1 and S3.

In particular, the upper and lower cutting holes 421 and 411 of apunching pattern to be formed in the lower plate 410 and the upper plate420 are integrally formed using a single molding element 501. Inaddition, the trimming hole 413 of the lower plate 410 is integrallyformed with the guide opening 422 by means of a molding element 502.

Here, the convex embossment 412 to be formed on the lower plate 410 isformed by the mold 500.

When the mold 500 configured as mentioned above is prepared, a meltedmetal such as zinc is then put into the mold to injection-mold a jig(S200).

FIG. 21 schematically shows a preform 600 of the injection-molded jig.As shown in FIG. 21, the lower plate 410 and the upper plate 420 areformed to be integrally connected with each other, and the lower andupper cutting holes 411 and 412 are interconnected and integrallyformed. In addition, the trimming hole 413 is integrally formed with theguide opening 422.

Subsequently, a side portion of the preform 600 of the jig is cut awayas much as the gap G to divide the lower plate 410 and the upper plate420, and at the same time a space for supplying a sheet member to bepunched is formed therebetween (S300). In FIG. 21, a portion that willbe removed by cutting is shown as a dotted line DL. Accordingly, thelower and upper cutting holes 411 and 421 are also separated on thelower plate 410 and the upper plate 420 respectively, and the trimminghole 413 is also separated from the guide opening 422.

According to the method wherein the lower plate 410 and the upper plate420 are integrally formed and then the gap G is formed between the lowerplate 410 and the upper plate 420 by cutting as mentioned above, thelower and upper cutting holes 411 and 421 and the trimming hole 413 maybe aligned very precisely. Otherwise, in the conventional technology inwhich the lower and upper cutting holes 411 and 421 and the trimminghole 413 are shaped in an injection molding process using a mold, amolded jig may be deformed due to distribution of melted materials ordifference of cooling rates, and accordingly the alignment of thecutting holes 411 and 421 and the trimming hole 413 may be deviated.

In this embodiment, in the cutting process, a portion of the perform 600higher than the upper surface of the convex embossment 412 is cut awayso that the convex embossment 412 which has been formed in advance inthe previous molding process may not damaged by a cutting blade.Accordingly, the upper surface 410 a of the lower plate 410 is higherthan the upper surface of the convex embossment 412. This process mayprevent the convex embossment 412 having a relatively elaborate patternfrom being damaged in the cutting process.

When the cutting process is completed, a jig as shown in FIG. 16 isproduced, and then a punching member 450 separately fabricated andvarious parts mentioned above are assembled (S400).

According to the punch manufacturing method of this embodiment, thelower and upper plates are integrally formed so that the lower and uppercutting holes of a pattern in the lower and upper plates are connectedwith each other, and then the lower and upper plates are separated bycutting so that the lower and upper cutting holes of a pattern may bealigned without any error. In addition, the jig is cut so as not tointerfere the convex embossment to thereby prevent the convex embossmentfrom being damaged or deformed by a cutter.

The present invention has been described in detail. However, it shouldbe understood that the detailed description and specific examples, whileindicating preferred embodiments of the invention, are given by way ofillustration only, since various changes and modifications within thespirit and scope of the invention will become apparent to those skilledin the art from this detailed description.

The punch according to the present invention may simultaneously punchand emboss a sheet member by only one stroke, thereby convenientlygiving various designs in which a punching pattern and an embossingpattern is mixed.

In addition, since the pins for punching or embossing may be associatedin various ways in the punch, it is possible to obtain various punchingand embossing designs, which cannot be expected in the prior art.

This punch may be used for punching a sheet member such as a card, aletter paper, a picture, a board, or a paper, which requires decoration,as well as for punching work in offices or industries, thereby improvingthe beauty thereof.

1. A method for manufacturing a punch, comprising the following stepsof: (a) injection-molding a jig with melted materials so that a lowerplate and an upper plate are integrally formed at least partially toconnect lower and upper cutting holes to be formed on the lower andupper plates respectively and also so that a convex embossment is formedon the lower plate; (b) cutting a connection portion of the lower andupper plates to form a gap through which a sheet member is to besupplied so that the lower and upper cutting holes are separated on thelower and upper plates respectively, and so that an upper surface of thelower plate is formed at the position higher than an upper surface ofthe convex embossment; and (c) assembling a punching member, whichincludes a first punch pin passing through the cutting holes to punchthe sheet member and form a predetermined pattern therein and a secondpunch pin having a concave embossment at a front end thereof incorrespondence to the convex embossment, to the jig.
 2. The method formanufacturing a punch according to claim 1, wherein a trimming hole onthe lower plate for cutting a marginal edge of the sheet member areintegrally formed with a guide opening on the upper plate for guidingvertical movement of a punch pin corresponding to the trimming hole inthe step (a), and the trimming hole and the guide opening are separatedby cutting in the step (b).